Headlamp switch removal - homemade tool

old_n_slo

This fabricated washer will remove your headlamp and washer controls from your dash without damage. Sure, go ahead and continue to use your needle nose pliers......or...

1. Grab a 9/16" washer from your bucket 'o fasteners.
2. With the edge of a file (or hacksaw) open up a gap.
3. File or Dremel a small relief where the pencil is pointed so it follows the curvature of the circular dash control nut.

Twist and shout!

The details:

a) Carefully pick your washer to ensure the correct "width"
b) Use a 15/64" drill to "gauge" your opening. That will be the size of the headlight switch shaft.

You know about using a nail to hold the shaft still, while twisting the knob to remove...right?

Enjoy!

Image may have been reduced in size. Click image to view fullscreen.

BWD · Posted: Wed Mar 24, 2010 4:35 pm Post subject:

Nice tip, beats the hell out of $20 something! Cool

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BWD
JHC
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1966 Beetle
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&Dan · Samba Member Joined: January 29, 2008 Posts: 1785

Pretty frickin' great!

How many other homemade VW-specific tools are out there?

Cusser · Posted: Wed Mar 24, 2010 8:49 pm Post subject:

Didn't someone take a nut driver and grind down the two sides leaving two little "pegs" ?
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1970 VW (owned since 1972) and 1971 VW Convertible (owned since 1976), second owner of each. The '71 now has the 1835 engine, swapped from the '70. Second owner of each. 1988 Mazda B2200 truck, 1998 Frontier, 2014 Yukon, 2004 Frontier King Cab. All manual transmission except for the Yukon. http://www.thesamba.com/vw/forum/album_page.php?pic_id=335294 http://www.thesamba.com/vw/forum/album_page.php?pic_id=335297

andk5591 · Posted: Thu Mar 25, 2010 2:57 am Post subject:

I like this - I had seen coupling bolts ground to have the 2 nubs - but nut driver idea is good too. Aren't we freakin geniuses? LOL. Good post - thanks
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D-Dubya Manx clone - 63 Short pan,1914.
Rosie 65 bug - My mostly stock daily driver.
Woodie 69 VW woodie (Hot VWs 7/12).
"John's car" 64 VW woodie - The first ever
Maxine 61 Cal-look bug - Cindy's daily driver.
Max - 73 standard Beetle hearse project - For sale
66 bug project - Real patina & Suby conversion
There's more, but not keeping them...

runamoc · Posted: Thu Mar 25, 2010 6:47 am Post subject:

Raul_MX · Posted: Thu Mar 25, 2010 6:51 am Post subject:

Can you please post a picture of the finished tool and while in use?

Regards.
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BajaCapt · Posted: Fri Mar 26, 2010 9:15 pm Post subject:

Hey! thanks for this post, I doing a search for headlight switch removal and ran into it, gave me a good idea to go about it.
I made my own tool out of a butter knife, I used a dremmel with a cut off wheel and a sanding bit for finishing it off, works like a charm! Cool

The tool and the things need it to make it ( about 20 minutes as well)

glutamodo · Posted: Fri Mar 26, 2010 10:39 pm Post subject:

Here's my home-made tool, made from a piece of stainless pipe:

kolt10 · Posted: Fri Mar 26, 2010 11:16 pm Post subject:

this is great. i was able to twist two of my mine off with my thumbs but i have one that i cant get. I will use this tomorrow.

kolt10 · Posted: Fri Mar 26, 2010 11:21 pm Post subject:

actually...im not now gonna make the tool. just used snap ring type pliers and they worked to fit in the slots

andk5591 · Posted: Sat Mar 27, 2010 10:40 am Post subject:

Made the washer tool yesterday since I was installing a light switch - worked great - and if I lose it, not biggy. Thanks
_________________
D-Dubya Manx clone - 63 Short pan,1914.
Rosie 65 bug - My mostly stock daily driver.
Woodie 69 VW woodie (Hot VWs 7/12).
"John's car" 64 VW woodie - The first ever
Maxine 61 Cal-look bug - Cindy's daily driver.
Max - 73 standard Beetle hearse project - For sale
66 bug project - Real patina & Suby conversion
There's more, but not keeping them...

Buck Naked · Posted: Sat Mar 27, 2010 11:09 am Post subject:

I think I hear the theme to `MacGyver` in the back ground. Laughing

Seriously these are some great ideas thanks for info.
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'63 Beetle Ragtop

old_n_slo · Posted: Sat Mar 27, 2010 1:27 pm Post subject:

If you need some more "gription" on the washer for torque, avoid the temptation to use pliers. They could slip and....well, I won't be responsible for scratches.

Vice grips.

grandpa pete · Posted: Sat Sep 20, 2014 5:11 pm Post subject:

or grind down an 8 mm deep socket Shocked

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66 sedan delivery Type 6

http://www.thesamba.com/vw/forum/viewtopic.php?t=569619&highlight=sedan+delivery

Aynthm · Posted: Sat Sep 20, 2014 11:11 pm Post subject:

Know how those little nuts that hold down the single port intake pipes are a bitch to get on and off due to the limited room and the lip on the bracket? Well I picked these nuts up at ACE and you can use a rachet on 'em, removal and installation is a snap.

AlohaFlyer · Posted: Fri Dec 05, 2014 2:47 am Post subject:

I made that tool and I am still having trouble getting those nuts to move... the previous owner painted the car without removing them, so I think that is partly why they won't move. I am afraid of stripping them... any ideas on how to get these to come off?

Thanks
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1967 VW Bug - Savannah Beige, 1600cc
1971 VW Campmobile - Neptune Blue, 2180cc
1982 VW Vanagon Westfalia - White
2005 VW Passat TDI - Silver

diablosandwich · Posted: Fri Dec 05, 2014 5:36 am Post subject:

Could you get some more torque if you used a tool like this?http://www.thesamba.com/vw/classifieds/detail.php?id=841285 instead of a small washer?
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1966 Java Greens

AlohaFlyer · Posted: Mon Dec 08, 2014 7:05 pm Post subject:

hitest · Posted: Mon Dec 08, 2014 7:48 pm Post subject:

I always just used needlenose pliers (the small 2-1/2" kind from cheap tool sales at gun shows). It moves the gripping surface out where an adult hand can hold it. I still have to be careful though.
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